Empirical Modeling of Average Cutting Speed during WEDM of Gas Turbine Alloy

Bhupinder Singh,Joy Prakash Misra,L.H Chen,Y Kondo

doi:10.1051/matecconf/201822101002

Bhupinder Singh, Joy Prakash Misra + Show 2 more

Open Access

https://doi.org/10.1051/matecconf/201822101002

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Abstract

Cutting speed (CS) is a key performance measure to achieve optimal utilization of the WEDM process. However, input process parameters of WEDM and combination of wire and workpiece material greatly hamper CS and hence productivity and machining efficiency. Therefore, it is essential to pick the right combination of parameters and wire and workpiece material to obtain better CS. In this paper, four process parameters: Ton, Toff, Sv, and Ip were chosen to develop an empirical model for CS during WEDM of nimonic 263 to provide a guideline to the potential users of the technique. This paper describes the response surface methodology (RSM) based mathematical modeling for average cutting speed. Furthermore, analysis of variance (ANOVA) was applied to find out significant process parameters and it was depicted that pulse on time and peak current were the major parameters affecting CS. In addition, WEDMed surfaces were analysed through FE-SEM at various discharge energy levels. The WEDMed surfaces appeared in the form of micro-cracks, craters, spherical droplets and the lump of debris. It is obvious from the current investigation that input parameters have the significant influence on cutting speed. The key features of experimental procedure are also highlighted in this paper.

Highlights

WEDM is one of the extensively accepted nonconventional machining processes employed to manufacture components with complex shapes, profile and sharp edges that are difficult-to-machine by other traditional and non-traditional machining processes [1] and this process has wide application areas including aerospace industry, medical implants, electronic industry, automobile industries, etc
Following conclusion has been drawn from the analysis of the results: 1. It has been observed that factor Ton is most significant input process parameter for Cutting speed (CS), followed by Ip
It was noticed that Toff and Sv have less significant effects on responses

Summary

Introduction

WEDM is one of the extensively accepted nonconventional machining processes employed to manufacture components with complex shapes, profile and sharp edges that are difficult-to-machine by other traditional and non-traditional machining processes [1] and this process has wide application areas including aerospace industry, medical implants, electronic industry, automobile industries, etc. It is an electro-thermal production type advanced machining process in which removal of material occurs due to melting and vaporization owing to a series of sparks between workpiece and wire electrode (thin copper, brass or tungsten of diameter 0.050.3 mm) submerged in a dielectric fluid (deionized water).

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